Tweco XTTM-301 Manuel d'utilisateur

Duty Cycle%Coolant Flow Minimum .9 GPHLIQUID COOLEDPLASMA CUTTING TORCHRev AC.01 Issue Date: December 20, 2006 Manual No. 0-4768Operating Features

GENERAL INFORMATION 1-4 Manual 0-47681.05 Precautions De SecuriteImportantesAVERTISSEMENTSL’OPÉRATION ET LA MAINTENANCE DUMATÉRIEL DE SOUDAGE À L’ARC

Manual 0-4768 1-5 GENERAL INFORMATIONINCENDIE ET EXPLOSIONLes incendies et les explosions peuvent résulter des scorieschaudes, des étincelles ou de l’

GENERAL INFORMATION 1-6 Manual 0-47681.06 Documents De ReferenceConsultez les normes suivantes ou les révisions les plusrécentes ayant été faites à ce

Manual 0-4768 1-7 GENERAL INFORMATION1.07 Declaration of ConformityManufacturer: Thermal Dynamics CorporationAddress: 82 Benning StreetWest Lebanon, N

GENERAL INFORMATION 1-8 Manual 0-47681.08 Statement of WarrantyLIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that

Manual 0-4768 2-1 INTRODUCTIONSECTION 2:INTRODUCTION2.01 Scope of ManualThis manual contains descriptions, operating instructions and maintenance proc

INTRODUCTION 2-2 Manual 0-47682.03 Torch Kit ContentsArt # A-07043All GasesAll Gases35-104135-1041XT-301™ Conventional Plasma TorchXT-301™ Conventiona

Manual 0-4768 2-3 INTRODUCTION2.04 Specifications & Design Features1. XTTM-301 Torch Configuration and Dimensions2.39"60.81 mm1.49"37.8

INTRODUCTION 2-4 Manual 0-47683. Cutting RangeMost materials up to 1 inch (25.4 mm)Up to 1/2 inch (12.7 mm) for production speed cutting4. Pierce Rati

Manual 0-4768 3-1 INSTALLATIONSECTION 3:INSTALLATION3.01 Kit ContentsThese kit configurations are available:Art # A-07043All GasesAll Gases35-104135-1

INSTALLATION 3-2 Manual 0-47683.02 Kit Applications:RemoteArcStarter> 25’ / 7.6m: Use XT-301 Torch Head and XT-301 Torch LeadsTorch Leads< 25’ /

Manual 0-4768 3-3 INSTALLATION3.04 XT-301 Torch Head Installation on MaximizerTM Leads (up to 25' long)The XT-301 torch head can be connected to

INSTALLATION 3-4 Manual 0-4768B. Install XT-301 TorchNOTEHandle the torch head carefully to avoid damage. The installer may chooseto follow Section 3

Manual 0-4768 3-5 INSTALLATION7. Press the Torch Head Assembly upward to connect to the positioning tube. Pull the leads back as needed toensure a p

INSTALLATION 3-6 Manual 0-47683.05 Connecting XT-301 Torch and Torch Leads (over 25' long) to Merlin 1000This section details connecting the XT-3

Manual 0-4768 3-7 INSTALLATIONSecondaryGasPlasma (+)GasControl CableConnectorCoolantSupply (-)CNC ControlCableRED Shield WiresWith Ring LugsTorch Lead

INSTALLATION 3-8 Manual 0-4768B. Connect XT-301 Leads to Merlin 1000 Power Supply WARNINGDisconnect primary power at the source before disassembling t

Manual 0-4768 3-9 INSTALLATIONSecondaryGasPlasma (+)GasControl CableConnectorCoolantSupply (-)CNC ControlCableRED Shield WiresWith Ring LugsTorch Lead

INSTALLATION 3-10 Manual 0-4768B. Connect XT-301 Torch Head to XT-301 Torch LeadsNOTEHandle the torch head carefully to avoid damage. The installer m

Manual 0-4768 3-11 INSTALLATION7. Press the Torch Head Assembly upward to connect to the positioning tube. Pull the leads back as needed toensure a

Read and understand this entire Manual and your employer’s safety practices before installing,operating, or servicing the equipment.While the informat

INSTALLATION 3-12 Manual 0-47683.06 Connecting XT-301 Torch and Torch Leads to Remote Arc StarterThe Torch Leads connect to a bulkhead inside the Remo

Manual 0-4768 3-13 INSTALLATION2. Disconnect the torch leads from the bulkhead panel inside the remote arc starter. The left illustration showssingle

INSTALLATION 3-14 Manual 0-4768B. Connect XT-301 Torch Leads to Remote Arc Starter1. Connect the torch leads connectors to the bulkhead connections pe

Manual 0-4768 3-15 INSTALLATIONC. Reverse Coolant Leads at the Power Supply1. Remove the power supply left side panel.Remove power supply left side pa

INSTALLATION 3-16 Manual 0-4768D. Install XT-301 TorchNOTEHandle the torch head carefully to avoid damage. The installer may chooseto follow Section

Manual 0-4768 3-17 INSTALLATIONShield ('Secondary') Gas ConnectorCoolant Supply ConnectorCoolant ReturnCheck Valve and ConnectorPlasma LeadC

INSTALLATION 3-18 Manual 0-47683.07 Install Consumable Torch Parts (All Applications)1. Check the appropriate cut chart for the right combination of p

Manual 0-4768 3-19 INSTALLATION5. Use the removal tool to hold the cartridge assembly, while turning the shield cup onto the cartridgeassembly. When

INSTALLATION 3-20 Manual 0-47687. Connect the wire lead from the height finder to the ohmic clip if using ohmic torch height sensing.NOTEOhmic sensing

Manual 0-4768 4-1 OPERATIONSECTION 4:OPERATION4.01 IntroductionThis Section provides a description of the XTTM-301 Torchfollowed by operating procedur

TABLE OF CONTENTSSECTION 1:GENERAL INFORMATION ... 1-11.0

Manual 0-4768 4-2 OPERATION4.04 Torch Parts SelectionThe metal to be cut and the plasma and secondary (shield) gases determine the torch parts to be u

Manual 0-4768 4-3 OPERATIONAir - AirOhmic Sensor9-9414O2 - AirCartridge35-1020N2 - H2OElectrodesPlasma GasDistributorsTipsShield GasDistributorsShiel

Manual 0-4768 4-4 OPERATION4.05 Torch MaintenanceA. Consumable Removal1. Use the removal tool to hold the Shield Cup & Cartridge Assembly station

Manual 0-4768 4-5 OPERATIONB. O-Ring LubricationLubricate all three O-Rings on the Cartridge Assembly and all three O-Rings on the Torch Head periodic

Manual 0-4768 4-6 OPERATIONC. Parts WearReplace the Gas Distributor if it is charred or cracked.Replace the Gas Distributor if the flange is damaged i

Manual 0-4768 4-7 OPERATIOND. Torch Consumables InstallationArt # A-03887

Manual 0-4768 4-8 OPERATION2. Remove the Removal Tool from the Cartridge and install the assembled Cartridge onto the Torch Head. CAUTIONThe cartrid

Manual 0-4768 4-9 OPERATIONE. Coolant Leak Trouble-ShootingNever operate the system if coolant leaks from the torch. A steady drip indicates that tor

Manual 0-4768 4-10 OPERATION4.06 Cut QualityNOTECut quality depends heavily on set-up and parameters such as torch standoff, alignment with the workpi

Manual 0-4768 4-11 OPERATIONH. Cut Quality on Various Materials and ThicknessesThe chart defines the typical cut quality on various materials and thic

TABLE OF CONTENTS (continued)5.06 Servicing Torch Components ... 5-95.07 Torch A

Manual 0-4768 4-12 OPERATION4.07 Operating the SystemWARNINGSDisconnect primary power at the source before disassembling the power supply, torch, or t

Manual 0-4768 4-13 OPERATIONE. DrossWhen dross is present on carbon steel, it is commonlyreferred to as either “high speed, slow speed, or topdross”.

Manual 0-4768 4-14 OPERATIONB. Travel SpeedProper travel speed is indicated by the trail of the arcwhich is seen below the plate. The arc can be one

Manual 0-4768 4-15 OPERATION4.08 Gas SelectionA. Plasma Gases1. Air Plasma• Most often used on ferrous or carbon base materials for good quality at fa

Manual 0-4768 4-16 OPERATION

Manual 0-4768 5-1 SERVICESECTION 5:SERVICE5.01 IntroductionThis Section describes basic maintenance procedures. Noother adjustments or repairs are t

SERVICE 5-2 Manual 0-47683. Excessive Dross Formationa. Cutting speed too slowb. Torch standoff too high from workpiecec. Worn torch partsd. Improper

Manual 0-4768 5-3 SERVICEB Consumable Removal1. Use the removal tool to hold the Shield Cup & Cartridge Assembly stationary. Turn the Shield Cup

SERVICE 5-4 Manual 0-4768C. Gas Distributor InspectionReplace the Gas Distributor if it is charred or cracked.Replace the Gas Distributor if flange i

Manual 0-4768 5-5 SERVICE5.04 Torch Consumables InstallationArt # A-03887

MetalAmperagePlasma GasShield ('Secondary')GasPageAir Air A-2O2 Air A-3Air Air A-4O2 Air A-555 Air Air A-6Air Air A-7H35 N2 A-8N2 H20 A-955

SERVICE 5-6 Manual 0-4768 2. Remove the Removal Tool from the Cartridge and install the assembled Cartridge onto the Torch Head. Confirmproper parts

Manual 0-4768 5-7 SERVICE5.05 Troubleshooting GuideA. TroubleshootingThis Sub-Section covers troubleshooting that requires disassembly and electronic

SERVICE 5-8 Manual 0-4768A. Torch will not pilot when torch switch is activated1. Power Supply RUN/SET switch in SET positiona. Place RUN/SET switch

Manual 0-4768 5-9 SERVICEF. No gas flow1. Gas not connected or pressure too lowa. Check source for proper input pressure.2. Faulty components in torc

SERVICE 5-10 Manual 0-4768B. Reassembling Torch Assembly1. Slide the replacement shrink-on tubing onto the torch leads assembly.2. Connect the plasma

Manual 0-4768 5-11 SERVICEShield ('Secondary') Gas ConnectorCoolant Supply ConnectorCoolant ReturnCheck Valve and ConnectorPlasma LeadConne

SERVICE 5-12 Manual 0-47685.07 Torch And Leads TroubleshootingA. General InformationFailures in the Torch and Leads can be isolated to the Torch Head

Manual 0-4768 5-13 SERVICE6. Check the torch leads by measuring the resistance between the positive pilot lead connector and the negativelead fittin

SERVICE 5-14 Manual 0-47684. Check the pilot lead, negative lead and switch con-trol wires for opens from one end of the torch leadsto the other.• If

Manual 0-4768 6-1 PARTS LISTSSECTION 6:PARTS LISTS6.01 IntroductionA. Parts List BreakdownThe parts list provides a breakdown of all replaceable com-p

Manual 0-4768 1-1 GENERAL INFORMATIONSECTION 1:GENERAL INFORMATION1.01 Notes, Cautions and WarningsThroughout this manual, notes, cautions, and warnin

PARTS LISTS 6-2 Manual 0-47686.03 Replacement Torch Parts and KitsItem # Qty Description Catalog #1 1 XT-301 Torch Head Assembly (Only) 35-10022 1 XT-

Manual 0-4768 6-3 PARTS LISTSArt # A-07056All GasesAll Gases35-104135-1041XT-301™ Conventional Plasma TorchXT-301™ Conventional Plasma Torch55A, MS55A

PARTS LISTS 6-4 Manual 0-47686.04 Torch ConsumablesAir - AirOhmic Sensor9-9414O2 - AirCartridge35-1020N2 - H2OElectrodesPlasma GasDistributorsTipsSh

Manual 0-4768 6-5 PARTS LISTS6.05 O-Rings for Torch ConsumablesO-Ring 9-9035O-Ring 9-9035O-Ring 9-9035O-Ring 9-9035O-Ring 9-9035O-Ring 9-9035O-Ring 9-

PARTS LISTS 6-6 Manual 0-4768This page is blank intentionally.

Manual 0-4768 A-1 APPENDIXSequence of Operation DiagramA-02175ACTIONClose externaldisconnect switchRESULT• Power to systemACTIONEnable ONON/OFF switc

APPENDIX A-2 Manual 0-4768Mild Steel55AAir Plasma / Air SecondaryArt # A-06741Tip35-1272ElectrodeShield Cap35-102535-105135-106935-1041CartridgeShield

Manual 0-4768 A-3 APPENDIXMild Steel55AO2 Plasma / Air SecondaryArt # A-06741Tip35-1272ElectrodeShield Cap35-102535-105135-106935-1041CartridgeShield

APPENDIX A-4 Manual 0-4768Mild Steel100AAir Plasma / Air SecondaryArt # A-06743Tip35-1272ElectrodeShield Cap35-102735-105335-107135-1041CartridgeShiel

Manual 0-4768 A-5 APPENDIXMild Steel100AO2 Plasma / Air SecondaryArt # A-06742Tip35-1272ElectrodeShield Cap35-102735-105335-107135-1041CartridgeShield

GENERAL INFORMATION 1-2 Manual 0-4768• Wear dry gloves and clothing. Insulate yourselffrom the work piece or other parts of the weldingcircuit.• Repa

APPENDIX A-6 Manual 0-4768Stainless Steel55AAir Plasma / Air SecondaryArt # A-06744Tip35-1272ElectrodeShield Cap35-103435-106035-107835-1041CartridgeS

Manual 0-4768 A-7 APPENDIXStainless Steel100AAir Plasma / Air SecondaryArt # A-06745Tip35-1272ElectrodeShield Cap35-102735-105335-107135-1041Cartridge

APPENDIX A-8 Manual 0-4768Stainless Steel100AH35 Plasma / N2 SecondaryArt # A-06746Tip35-1272ElectrodeShield Cap35-103435-106235-108035-1041CartridgeS

Manual 0-4768 A-9 APPENDIXNOTEOhmic sensing is not recommended with water shield. Water on theplate interferes electrically with the ohmic sensing sy

APPENDIX A-10 Manual 0-4768Aluminum55AAir Plasma / Air SecondaryArt # A-06748Tip35-1272ElectrodeShield Cap35-103435-106035-107835-1041CartridgeShield

Manual 0-4768 A-11 APPENDIXAluminum100AAir Plasma / Air SecondaryArt # A-06749Tip35-1272ElectrodeShield Cap35-102735-105335-107135-1041CartridgeShield

APPENDIX A-12 Manual 0-4768Aluminum100AN2 Plasma / H2O SecondaryNOTEOhmic sensing is not recommended with water shield. Water on theplate interferes

Manual 0-4768 A-13 APPENDIXAluminum100AH35 Plasma / N2 SecondaryArt # A-06750Tip35-1272ElectrodeShield Cap35-103435-106235-108035-1041CartridgeShield

APPENDIX A-14 Manual 0-4768PATENT INFORMATIONXTTM-301 Plasma Cutting Torch PatentsThe following parts are covered under U.S. and Foreign Patents as fo

Manual 0-4768 A-15 APPENDIXXTTM-301 Plasma Cutting Torch PatentsThe following parts are covered under U.S. and Foreign Patents as follows:Catalog # De

Manual 0-4768 1-3 GENERAL INFORMATION6. ANSI Standard Z49.2, FIRE PREVENTION IN THEUSE OF CUTTING AND WELDING PROCESSES, ob-tainable from American Nat

Manual No. 0-4768 A-16 AppendixPublication HistoryManual No. 0-4768Cover Date Rev Change(s)8/29/05 First issue.9/10/05 Corrected metric measurement

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